U.S. patent number 8,659,191 [Application Number 13/110,772] was granted by the patent office on 2014-02-25 for sleeve member for an electric machine.
This patent grant is currently assigned to Remy Technologies, LLC. The grantee listed for this patent is Bradley D. Chamberlin, James Ramey. Invention is credited to Bradley D. Chamberlin, James Ramey.
United States Patent |
8,659,191 |
Chamberlin , et al. |
February 25, 2014 |
Sleeve member for an electric machine
Abstract
Embodiments of the invention provide an electric machine module
including a module housing. The module housing can include a sleeve
member coupled to at least one end cover and can define a machine
cavity. In some embodiments, the sleeve member can include an inner
perimeter and can be coupled to a stator assembly of an electric
machine. In some embodiments, the electric machine can be
positioned within the machine and at least partially enclosed by
the module housing. In some embodiments, a coolant jacket can be
defined by at least a portion of the sleeve member and at least a
portion of the stator assembly.
Inventors: |
Chamberlin; Bradley D.
(Pendleton, IN), Ramey; James (Fortville, IN) |
Applicant: |
Name |
City |
State |
Country |
Type |
Chamberlin; Bradley D.
Ramey; James |
Pendleton
Fortville |
IN
IN |
US
US |
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Assignee: |
Remy Technologies, LLC
(Pendleton, IN)
|
Family
ID: |
44971921 |
Appl.
No.: |
13/110,772 |
Filed: |
May 18, 2011 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20110285222 A1 |
Nov 24, 2011 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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61345946 |
May 18, 2010 |
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Current U.S.
Class: |
310/54; 310/52;
310/58 |
Current CPC
Class: |
H02K
9/19 (20130101); H02K 5/20 (20130101) |
Current International
Class: |
H02K
9/00 (20060101); H02K 9/20 (20060101) |
Field of
Search: |
;310/52,54,58 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
International Search Report, Received Feb. 16, 2012. cited by
applicant.
|
Primary Examiner: Kim; John K
Attorney, Agent or Firm: Cantor Colburn LLP
Parent Case Text
RELATED APPLICATIONS
This application claims priority under 35 U.S.C. .sctn.119 to U.S.
Provisional Patent Application No. 61/345,946 filed on May 18,
2010, the entire contents of which is incorporated herein by
reference.
Claims
The invention claimed is:
1. An electric machine module comprising: an electric machine
including a stator assembly with stator end turns and a rotor
assembly, the stator assembly circumscribing at least a portion of
the rotor assembly; a sleeve member operatively coupled to at least
a portion of the stator assembly, the sleeve member substantially
circumscribing at least a portion of the stator assembly, and the
sleeve member including an outer perimeter; a module housing;
Including a canister and at least one end cover, the canister being
distinct from and coupled to the at least one end cover and an
inner perimeter of the module housing, at least a portion of the
module housing defining a machine cavity, the canister including an
inner perimeter, and the electric machine positioned substantially
within the machine cavity so that the electric machine is at least
partially enclosed by the module housing and at least a portion of
the sleeve member is immediately adjacent to at least a portion of
the inner perimeter of the canister; and a coolant jacket defined
by at least a portion of the outer perimeter of the sleeve member
and at least a portion of the inner perimeter of the canister.
2. The electric machine module of claim 1 and further comprising a
plurality of coolant apertures positioned through a portion of the
sleeve member so that the coolant jacket is in fluid communication
with the machine cavity.
3. The electric machine module of claim 2, wherein the plurality of
coolant apertures are positioned substantially adjacent to at least
a portion of the stator end turns.
4. The electric machine module of claim 1 and further comprising at
least one feature.
5. The electric machine module of claim 4, wherein at least one of
the outer perimeter of the sleeve member and the inner perimeter of
the canister comprises the at least one feature.
6. The electric machine module of claim 1, wherein the sleeve
member comprises at least one first groove.
7. The electric machine module of claim 1, wherein the sleeve
member comprises at least one stator retainer.
8. The electric machine module of claim 1 and further comprising at
least one drain positioned through a portion of the canister, the
at least one drain in fluid communication with at least one of the
coolant jacket and the machine cavity.
9. The electric machine module of claim 1, wherein the sleeve
member comprises stainless steel.
Description
BACKGROUND
Some electric machines are housed within a module housing. Some
module housings includes a canister with an enclosed end and an
open end, and the electric machine can be positioned inside the
canister through the open end. The module housing also includes a
cover that can be placed over the open end of the canister to
enclose the electric machine within the canister. Some methods for
cooling the electric machine can include circulating a coolant
around a portion of the electric machine inside of a cooling
jacket. At least a portion of the cooling jacket can be defined by
at least a portion of the module housing.
SUMMARY
Some embodiments of the invention provide an electric machine
module including a module housing. The module housing can include a
sleeve member coupled to at least one end cover and can define a
machine cavity. In some embodiments, the sleeve member can include
an inner perimeter and can be coupled to a stator assembly of an
electric machine. In some embodiments, the electric machine can be
positioned within the machine and at least partially enclosed by
the module housing. In some embodiments, a coolant jacket can be
defined by at least a portion of the sleeve member and at least a
portion of the stator assembly.
Some embodiments of the invention provide an electric machine
module including an electric machine. In some embodiments, the
electric machine can include a stator assembly. In some
embodiments, a sleeve member can be operatively coupled to at least
a portion of the stator assembly. In some embodiments, at least a
portion of the electric machine can be positioned within a module
housing, which can include a canister coupled to at least one end
cover. In some embodiments, the electric machine can be positioned
substantially within the module housing so that at least a portion
of the sleeve member is adjacent to at least a portion of the
canister. In some embodiments, a coolant jacket can be defined
between at least a portion of the sleeve member and at least a
portion of the canister.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional view of an electric machine
module according to one embodiment of the invention.
FIG. 2 is a partial cross-sectional view of an electric machine
module according to another embodiment of the invention.
FIG. 3 is a perspective view of a stator sleeve according to one
embodiment of the invention.
FIG. 4 is a perspective view of a stator sleeve according to
another embodiment of the invention.
FIG. 5 is a perspective view of a stator inside the stator sleeve
of FIG. 3.
FIG. 6 is a side view of a stator inside the stator sleeve of FIG.
3.
FIG. 7 is an exploded perspective view of an electric machine
module according to one embodiment of the invention.
DETAILED DESCRIPTION
Before any embodiments of the invention are explained in detail, it
is to be understood that the invention is not limited in its
application to the details of construction and the arrangement of
components set forth in the following description or illustrated in
the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting. The use of "including,"
"comprising," or "having" and variations thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items. Unless specified or limited otherwise,
the terms "mounted," "connected," "supported," and "coupled" and
variations thereof are used broadly and encompass both direct and
indirect mountings, connections, supports, and couplings. Further,
"connected" and "coupled" are not restricted to physical or
mechanical connections or couplings.
The following discussion is presented to enable a person skilled in
the art to make and use embodiments of the invention. Various
modifications to the illustrated embodiments will be readily
apparent to those skilled in the art, and the generic principles
herein can be applied to other embodiments and applications without
departing from embodiments of the invention. Thus, embodiments of
the invention are not intended to be limited to embodiments shown,
but are to be accorded the widest scope consistent with the
principles and features disclosed herein. The following detailed
description is to be read with reference to the figures, in which
like elements in different figures have like reference numerals.
The figures, which are not necessarily to scale, depict selected
embodiments and are not intended to limit the scope of embodiments
of the invention. Skilled artisans will recognize the examples
provided herein have many useful alternatives that fall within the
scope of embodiments of the invention.
FIG. 1 illustrates a portion of an electric machine module 10
according to one embodiment of the invention. In some embodiments,
the module 10 can include a module housing 12 comprising a sleeve
member 14, a first cover 16, and a second cover 18. At least a
portion of an electric machine 20 can be housed within a machine
cavity 22 at least partially defined by the module housing 12. For
example, the sleeve member 14 and the end caps 16, 18 can be
coupled via conventional fasteners 13, or another coupling method,
to enclose at least a portion of the electric machine 20 within the
machine cavity 22. Moreover, in some embodiments, at least one of
the end covers 16, 18 can be integral with the sleeve member 14. As
discussed in further detail below, in some embodiments the module
housing 12 can comprise a substantially cylindrical canister 15 and
at least one end cover 17, as shown in FIG. 2. Further, in some
embodiments, the module housing 12 can comprise materials that can
generally include thermally conductive properties, such as, but not
limited to aluminum or other metals and materials capable of
generally withstanding operating temperatures of the electric
machine 20. In some embodiments, the module housing 12 can be
fabricated using different methods including casting, molding,
extruding, and other manufacturing methods.
The electric machine 20 can include a rotor assembly 24, a stator
assembly 26, including stator end turns 28, and bearings 29, and
can be disposed about an output shaft 33. As shown in FIG. 1, the
stator 26 can substantially circumscribe the rotor 24. In some
embodiments, the rotor assembly 24 can also include a rotor hub 31
or can have a "hub-less" design, as shown in FIG. 2. In some
embodiments, at least a portion of an inner diameter of the rotor
assembly 24 can comprise a plurality of splines configured and
arranged to matingly engage with a plurality of splines on the
output shaft 34 and/or an input shaft (not shown).
The electric machine 20 can be, without limitation, an electric
motor, such as a hybrid electric motor, a starter motor, an
electric generator, or a vehicle alternator. In one embodiment, the
electric machine 20 can be a High Voltage Hairpin (HVH) electric
motor or an interior permanent magnet electric motor for hybrid
vehicle applications.
Components of the electric machine 20 such as, but not limited to,
the rotor assembly 24, the stator assembly 26, and the stator end
turns 28 can generate heat during operation of the electric machine
20. These components can be cooled to increase the performance and
the lifespan of the electric machine 20.
In some embodiments, the sleeve member 14 can comprise a
substantially annular shape and can include an inner perimeter 30
and an outer perimeter 32. In some embodiments, the sleeve member
14 can comprise other shapes such as, but not limited to,
elliptical, hemispherical, regular or irregular polygonal, or any
combination thereof. In some embodiments, at least a portion of the
sleeve member 14 can comprise a shape substantially similar to a
shape of at least a portion of the stator assembly 26. In some
embodiments, the sleeve member 14 can comprise stainless steel,
aluminum, cast aluminum, copper, and other materials. In some
embodiments, at least a portion of the sleeve member inner
perimeter 30 can be operatively coupled to an outer perimeter 34 of
the stator assembly 26, so that the sleeve member 14 and the stator
assembly 24 are substantially retained in a position relative to
one another, as shown in FIGS. 1-2 and 5-6. For example, in some
embodiments, the sleeve member 14 can substantially circumscribe at
least a portion of the stator assembly 26. By way of example only,
in some embodiments, the stator assembly 26 and the sleeve member
14 can be friction fit, interference fit, welded, brazed, or
otherwise coupled together. In some embodiments, one or more
elements, such as a stator retainer 36 (as shown in FIG. 6), can
provide an interface between the sleeve member 14 and the stator
assembly 26 so that the stator assembly 26 can be coupled to the
sleeve member 14 and at least a portion of the torque produced
during electric machine operations can be transmitted between at
least these components.
As shown in FIG. 1, in some embodiments, the electric machine
module 10 can include a coolant jacket 38. In some embodiments, at
least a portion of the sleeve member 14 and at least a portion of
the outer perimeter 34 of the stator assembly 26 can at least
partially define the coolant jacket 38. In some embodiments, the
coolant jacket 38 can receive a coolant from a coolant source (not
shown) via at least one coolant inlet (not shown). In some
embodiments, the coolant jacket 38 can contain the coolant that can
comprise transmission fluid, ethylene glycol, an ethylene
glycol/water mixture, water, oil, motor oil, or a similar
substance. In some embodiments, the coolant can comprise a gas
and/or mist. For example, in some embodiments, the coolant jacket
38 can be defined between the sleeve member inner perimeter 30 and
the stator assembly outer perimeter 34 and can receive the coolant
from the coolant source. In some embodiments, the sleeve member
inner perimeter 30 and/or the stator assembly outer perimeter 34
can comprise o-rings and/or other sealing structures (not shown) to
provide sealing surfaces to substantially seal the coolant jacket
38 from other portions of the module 10. In some embodiments, the
coolant jacket 38 can substantially circumscribe at least a portion
of the stator assembly 26.
FIG. 2 illustrates the electric machine module 10 according to
other embodiments of the invention. As shown in FIG. 2, the
electric machine module 10 can comprise the sleeve member 14 and
the module housing 12 can include the canister 15 and the end cover
17. In some embodiments, the canister 15 can comprise an open end
and a closed end. In other embodiments, the canister 15 can
comprise two substantially open ends and an additional end cover
(not shown) coupled to at least one of the open ends to
substantially form the canister 15. In some embodiments, the sleeve
member 14 and the canister 15 can be coupled together before
coupling together the sleeve member 14 and the stator assembly 26.
In other embodiments, the sleeve member 14 and the canister 15 can
be coupled together after and/or substantially simultaneously to
the coupling together of the sleeve member 14 and the stator
assembly 26. In some embodiments, the sleeve member 14 can be
immediately adjacent to the canister 15 so that portions of the
sleeve member 14 and the canister 15 can substantially contact each
other. In some embodiments, the sleeve member 14 and the canister
15 can be coupled together so that the coolant jacket 38 can be
defined between at least a portion of the sleeve member 14 and at
least a portion of the canister 15. For example, in some
embodiments, at least a portion of the sleeve member outer
perimeter 32 and at least a portion of an inner perimeter 40 of the
canister 15 can define the coolant jacket 38. In some embodiments,
at least one coolant inlet (not shown) can be positioned through a
portion of the canister 15 and/or end cover 17 so that coolant can
be circulated through the coolant jacket 38 from a coolant source
(not shown). In some embodiments, the sleeve member outer perimeter
32 and/or the canister inner perimeter 40 can comprise o-rings
and/or other sealing structures (not shown) to provide sealing
surfaces to substantially seal the coolant jacket 38 from other
portions of the module 10. For example, in some embodiments, at
least one o-ring can be positioned in at least one first groove 42
defined around at least a portion of the sleeve member outer
perimeter 32, as shown in FIG. 2.
In some embodiments, as shown in FIGS. 1-5, at least one mount 44
can be located between the sleeve member 14 and an additional
housing 46 (e.g., a transmission housing, a motor housing, an
additional motor housing, another machine housing, etc.) or the
canister 15, respectively, to substantially retain the sleeve
member 14 in position and to aid in transmitting at least a portion
of the torque produced during the operation of the electric machine
20. In addition, in some embodiments, o-rings or other sealing
structures can be positioned in at lease one second groove 46
located substantially between at least a portion of the sleeve
member outer perimeter 32 and at least a portion of the additional
housing 46.
In some embodiments, different portions of the sleeve member 14 can
define at least a portion of the coolant jacket 38. For example, as
previously mentioned, in some embodiments, the coolant jacket 38
can be defined by at least a portion of the sleeve member perimeter
30, as shown in FIG. 1, at least a portion of the sleeve member
outer perimeter 32, as shown in FIG. 2, or can be substantially
internally positioned with respect to the sleeve member 14 (not
shown).
As previously mentioned, in some embodiments, the stator sleeve 14,
the canister 15, and/or the additional housing 46 can comprise at
least one coolant inlet to allow coolant flow into the coolant
jacket 38. In some embodiments, the coolant can be directed into
the coolant jacket 38 and can circulate through at least a portion
of the coolant jacket 38 to remove at least a portion of the heat
energy produced by the electric machine 20. For example, in some
embodiments, the coolant circulating through the coolant jacket 38
can remove at least a portion of the heat energy produced by the
stator assembly 26 because the coolant jacket 38 can substantially
circumscribe at least a portion of the stator assembly 26.
As shown in FIGS. 3 and 4, in some embodiments, the sleeve member
14 can comprise a plurality of coolant apertures 50 so that the
coolant jacket 38 is in fluid communication with the machine cavity
22. In some embodiments, the coolant apertures 50 can be positioned
substantially adjacent to the stator end turns 28 (e.g., radially
outward, radially inward, axially inward, a combination thereof,
etc.) so that at least a portion of the coolant circulating through
the coolant jacket 38 can directed toward the stator end turns 28.
In some embodiments, after exiting the coolant jacket 38 through
the coolant apertures 50, at least a portion of the coolant can
flow through portions of the machine cavity 22 can contact elements
of the module 10 to remove at least a portion of the heat energy
produced during and after electric machine operations.
As shown in FIGS. 3 and 5, in some embodiments, the sleeve member
14, the outer perimeter of the stator assembly 34, and/or the inner
perimeter of the canister 40 can comprise at least one feature 52.
Although future references to feature 52 are singular, in some
embodiments, the module 10 can comprise a plurality of features 52.
In some embodiments, the feature 52 can extend from the sleeve
member 14, the outer perimeter of the stator assembly 34, and/or
the inner perimeter of the canister 40 into the coolant jacket 38
to direct the coolant flow throughout the coolant cavity 38 in a
variety of directions, creating a more turbulent flow. Also, in
some embodiments, the feature 52 can provide more surface area from
which heat energy can be transferred from module 10 to the coolant.
In some embodiments, the feature 52 can comprise a substantially
rectangular shape in a substantially axially directed orientation,
and in other embodiments, the feature 52 can comprise other shapes
and can be oriented in other directions (e.g., axially, radially, a
combination thereof, etc.). Moreover, in some embodiments, the
feature 52 can comprise a recessed shape with respect to the
coolant jacket 38 (e.g., substantially radially inward and radially
outward with respect to the coolant jacket 38). In some
embodiments, the module 10 can comprise features 52 including a
combination of shapes and sizes. As a result of more turbulent flow
and increased heat transfer surface area, the coolant can make more
contact with the sleeve member 14 and remove additional levels of
heat form the electric machine module 10.
In some embodiments, the coolant can exit the coolant jacket 38
and/or the machine cavity 22 through a drain 48, as shown in FIGS.
3 and 4. In some embodiments, the drain 48 can be positioned
through a portion of the sleeve member 14, the canister 15, or
other portions of the module housing 12. In some embodiments, the
drain 48 can be in fluid communication with at least one of the
coolant jacket 38 and the machine cavity 22 so that at least a
portion of the coolant within the machine cavity 22 and/or the
coolant jacket 38 can exit the module 10. In some embodiments, the
coolant can exit the module 10 through the drain 48, which can be
fluidly connected to a heat exchange element (not shown). As a
result, in some embodiments, at least a portion of the heat energy
received by the coolant can be removed at the heat exchange element
and at least a portion of the coolant can be re-circulated to the
module 10.
It will be appreciated by those skilled in the art that while the
invention has been described above in connection with particular
embodiments and examples, the invention is not necessarily so
limited, and that numerous other embodiments, examples, uses,
modifications and departures from the embodiments, examples and
uses are intended to be encompassed by the claims attached hereto.
The entire disclosure of each patent and publication cited herein
is incorporated by reference, as if each such patent or publication
were individually incorporated by reference herein. Various
features and advantages of the invention are set forth in the
following claims.
* * * * *